Camera handling system

ABSTRACT

A test handler is controlled by a tester to transport, select, focus and test miniature digital camera modules. The modules are loaded onto a transport tray and moved on a conveyer to a robot. The robot selects the untested modules from the tray an alternately places the modules into two test stations. A first test station focuses and tests a first module while the second test station is loaded with a second module, thus burying the handling time for the modules within the test time. The robot returns tested modules to the transport tray, and when all modules on the tray are tested, moves the tray out of the test handler. A second tray with untested modules is positioned at the robot while the tested modules of the first tray are being focus fixed and sorted into part number bins. The overlap of operations buries handling time within the focus and test time so that the limitation of total test time is depending on focus and test operations.

RELATED PATENT APPLICATION

This application is related to U.S. patent application Ser. No.10/930,351, filed on Aug. 31, 2004, and assigned to the same assignee asthe present invention.

This application is related to U.S. patent application Ser. No.10/930,353, filed on Aug. 31, 2004, and assigned to the same assignee asthe present invention.

This application is related to U.S. patent application Ser. No.10/929,652, filed on Aug. 31, 2004, and assigned to the same assignee asthe present invention.

This application is related to U.S. patent application Ser. No.10/929,300, filed on Aug. 31, 2004, and assigned to the same assignee asthe present invention.

This application is related to U.S. patent application Ser. No.10/929,653, filed on Aug. 31, 2004, and assigned to the same assignee asthe present invention.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to module testing and in particular to thehandling of miniature digital camera modules during focus and testoperations.

2. Description of Related Art

The digital camera is becoming a ubiquitous device. Not only are digitalcameras replacing the traditional film camera, digital camera devicesare being used in many other applications, such as small electronicdevices, such as PDA (personal data assistant) and cellular phones. Withthe explosion of cellular phones, the ability to take a picture and thensend that picture to another individual using a second cellular phonecomes the need to produce inexpensive digital camera modules andefficiently test these modules in large quantities. This is furthercomplicated by the many different module configurations that areemerging as a result of the many different application requirements,including fixed focus, manual focus and automatic focus as well asphysical size. Some of these modules are very small and others havesignal leads in the form of a flex filmstrip. The testing time fordigital camera module, which can have mega-pixel capability, hastraditionally been a relatively long process (approximately sixtyseconds for a module with 0.3 megapixels) to insure the integrity andpicture quality of the camera. Quality testing at a low cost has becomethe utmost of importance. This necessitates a testing capability that isfast and insures the integrity and specification of the digital cameramodule while testing a large quantity of modules.

A patent application, Ser. No. 10/417,317 dated Apr. 16, 2003, isrelated to miniature cameras and their manufacturing methods that areused as built-in modules in hand held consumer electronics devices suchas mobile phones and PDA's. In a second patent application, Ser. No.10/434,743 dated May 8, 2003, a test system is described for digitalcamera modules used as built-in modules for consumer electronics, whichperforms electrical tests, adjustment of focus and sealing of the lensbarrel with glue.

In addition there are a number of other prior art patents that aredirected to testing of digital cameras: US 20040032496A1 (Eberstein etal.) is directed to a method of camera calibration and quality testing;EP 1389878A1 (Bednarz et al.) is directed to a method of cameracalibration and testing camera quality; US 20040027456A1 (Pierce)directed to the use of calibration targets; EP 1382194A1 (Baer) isdirected to dark current subtraction; JP 2003259126 (Keisuke) isdirected to removing noise of an image; US 20030146976A1 (Liu) isdirected to a digital camera system enabling remote monitoring; JP2003219436 (Fuminori) is directed to adjustment of a pixel shift camera;US 2003142374 (Silverstein) is directed to calibrating output of animage output device; JP 2003179949 (Hidetoshi) is directed to aluminance level inspection apparatus; JP 2003157425 (Vehvilainen) isdirected to improving image quality produced in a mobile imaging phone;JP 2003101823 (Kenichi) is directed to specifying a picture data area;EP 1286553 A2 (Baer) is directed to a method and apparatus for improvingimage quality; US 20030030648 (Baer) is directed to a method andapparatus for improving image quality in digital cameras; U.S. Pat. No.6,512,587 (Marcus et al.) is directed to measurement method andapparatus of an imager assembly; US 20030002749 (Vehvilainen) isdirected to a method and apparatus for improving image quality; US20020191973 A1 (Hofer et al.) is directed to a method and apparatus forfocus error reduction; WO 2002102060 A1 (Baer) is directed to a methodand apparatus for smear in digital images using a frame transfer sensor;JP 2002290994 (Hidetoshi) is directed to a method and apparatus todetect foreign matter on the surface of a lens; JP 200223918 (Yanshinao)is directed to an image inspection device and method for a cameramodule; JP 2002077955 (Keisuke) is directed to a method and apparatusfor evaluating camera characteristics; JP 2001292461 (Keisuke) isdirected to a system and method for evaluating a camera; U.S. Pat. No.6,219,443 B1 (Lawrence) is directed to a method and apparatus forinspecting a display using a low resolution camera; U.S. Pat. No.6,201,600B1 (Sites et al.) is directed to a method and apparatus forinspection of optically transmissive objects having a lens; U.S. Pat.No. 5,649,258 (Bergstresser et al.) is directed to an apparatus andtesting of a camera; EP 0679932 B1 (Kobayashi et al.) is directed totesting an electronically controlled camera; U.S. Pat. No. 5,179,437(Kawada et al.) is directed to an apparatus for color correction ofimage signals of a color television camera; JP 03099376 (Hiroshi) isdirected to the quality of a display screen; U.S. Pat. No. 4,612,666(King) is directed to a pattern recognition apparatus; and U.S. Pat. No.4,298,944 Stoub et al.) is directed to a method and apparatus fordistortion correction for scintillation cameras.

SUMMARY OF THE INVENTION

It is an objective of the present invention to provide a test handlerthat coupled with the test routines of a tester reduces the test time byapproximately an order of magnitude with respect to the prior art.

It is also an objective of the present invention to provide an apparatusand method to automatically handle miniature digital camera modulesduring focus and test operations.

It is further an objective of the present invention to bury the handlingtime of the digital camera modules within the focus and test time of thedigital camera module.

It is still further an objective of the present invention test a firstmodule in a first test station while loading a second module into asecond test station.

It is also an objective of the present invention to permanently fix thefocus of the digital camera module that has been focused by theapparatus of the test handler.

A test handler coupled to a tester provides a capability of positioninga tray containing a plurality of digital camera modules at a point neara robot. The modules are accurately positioned in the tray to facilitatethe placement of a module under test (MUT) into a test fixture, which isallows alignment of the modules with the optics system of the handlerand the electrical contactor that provides electrical signals. The robotselects a first digital camera module from the tray and positions themodule in a test fixture of a first test station. The module isoptically aligned with the optics system of the first test station andelectrical contact is made to the I/O pins of the module. On some typesof modules the I/O pins are on a flex-strip connected to the module. Onother types the I/O pins are on the body of the digital camera module.Once the optical alignment and the electrical connections are made, DCtests are performed on the MUT. Then the MUT requiring manual focusadjustment is focused using focus targets and a focus unit to change thefocus adjustment of the MUT. The focus adjustment is left in placeduring the subsequent optical testing and is permanently fixed after alldigital camera modules on the tray have been focused and tested.

While a first MUT is being focused and tested in the first test station,a second MUT is chosen from the tray by the robot and aligned with thesecond test station. Once testing is completed on the first MUT, focusand testing is started on the second MUT. The first MUT is returned tothe tray, and a third MUT is placed into the first test station. Thisalternate use of the two test stations allows the handling time to beburied under the focus and test time.

After test is complete on all digital camera module contained on firsttray. The first tray is moved to a lens fixing and part number binningarea. A second tray is then moved to the alignment mark for selection bythe robot of the digital camera modules contained therein for electricaland optical tests. The lens on digital camera modules of the first tray,which have been manually adjusted in a test station, are permanentlyfixed in place using glue or other techniques such as laser welding ofthe lens cap to the module body or physically pinning the cap to themodule body. After the lens of all the digital camera modules in thefirst tray has been permanently fixed, the modules in the first tray aresorted into part number bins (called binning). While the modulescontained on the second tray are being tested, a third tray is beingloaded with additional module to be moved to the alignment mark at therobot when the second tray is moved to the lens fixing and binningareas. Thus the loading operation of the third tray and unloadingoperation (focus fixing and binning) of the first tray are buried withinthe focus and test time of modules on the second tray.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention will be described with reference to the accompanyingdrawings, wherein:

FIG. 1 is a diagram of the present invention showing a test handlercoupled to a tester,

FIG. 2 is a floor plan of the handler of the present invention,

FIG. 3 is a diagram of the handling tray containing digital cameramodules of the present invention and resting on a platform for conveyingthe tray through the test handler,

FIG. 4 is a diagram of a portion of a tray of digital camera modules ofthe present invention with the flex-leads positioned on the tray,

FIGS. 5A and 5B are diagrams of the vacuum pick up unit of a robot usedto select a module from a tray and position the module in a test fixtureof the present invention,

FIG. 6A is a diagram of a MUT clamped in place on a test fixture of atest station of the present invention,

FIG. 6B is a diagram of the electrical contact made between the teststation and the flex-leads of the MUT of the present invention,

FIG. 7 is a diagram of a portion of the optics system of a test stationof the present invention and a MUT in the test fixture that has finishedtest,

FIGS. 8A and 8B are diagrams of the present invention of the focusapparatus in contact with the MUT,

FIG. 9 is a flow diagram of the method of focus adjustment to a MUTpositioned in a test fixture,

FIG. 10 is a flow diagram of the method of transporting digital cameramodules, and

FIG. 11 is a flow diagram of the method of the handling of digitalcamera modules within the test handler.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows basic concept of a digital camera module test system of thepresent invention in which a tester 33 controls the operation of ahandler 30 and receives back from the handler tested modules and dataresult from the tests corresponding to the tested modules. The handler30 contains two customized test stations 31 that are electricallycoupled to the tester 33. The test stations are customized toaccommodate the shape and electrical leads of a particular digitalcamera module. Each test station 31 can be configured to test the sametype or different types of digital camera modules depending upon therequirements of the manufacturing test line.

A tray handier 34 is used to transport a metal tray, which contains aplurality of miniature digital camera modules, which are accuratelypositioned on the tray, through the handler. The tray of digital cameramodules is position at an alignment mark so that a robot 32 can remove adigital camera module from the tray and place the module into either ofthe two test stations 31. A digital camera module is placed into thetest fixture using a vacuum unit attached to the robot 32, and thedigital camera module is optically aligned in the test station. Theoptics system of the test station includes a light source 35 containinga minimum of four different colors (red, blue, green and infrared),target holders 36 used to hold targets that are used for testing and oradjusting the focus of the digital camera module under test (MUT) and afield lens 37. The field lens produces a virtual focus distance from theMUT of the focus targets contained in the target wheels 36, which makesthe targets used in focus testing of the MUT to appear to be moredistant from MUT than the physical distance between the MUT and thetargets. A contact unit 38 connects to the electrical contacts of theMUT to allow the tester to apply electrical signals and obtain test dataincluding test pictures. The focus unit 38 is used to adjust the focusof a MUT having a manual focus capability by physically adjusting thelens cap 20 on the MUT. In a MUT with and automatic adjustable focus, anelectrical signal applied to the MUT is used to adjust the focus overthe focus range of the MUT.

FIG. 2 is a diagram of the present invention showing a floor plan of thehandler 30 located within a first test system 70 and connected to atester 33. A location of second test system 71 is shown connected to thebinning 72 and lens fixing 73 areas used by the first test system. Acarrying tray 69 is used to carry untested modules to the handler 30 andis unloaded into a metal tray 74 for transport of digital camera modules78 through the handler. The carrying tray 69 can be of any suitablematerial for carrying modules to and from the handler, but is not of adesign or material with sufficient dimensional accuracy to be used within the handler. The metal tray 74 is designed for dimensional stabilityand accurate alignment of the modules 78 to accommodate the ability ofthe robot 32 to select a module and orient the module in a test fixture80. Other material than metal is within the scope of the presentinvention to be used in place of the metal tray 74, but the non-metalmaterial must be able to accommodate the tolerances required by thehandler. The metal tray 74 contains a plurality of digital cameramodules 78 that are accurately positioned on the metal tray. The metaltray 74 is placed on a transport mechanism of the conveyer 75 at a “trayin” location 76 and is moved to an alignment location 79 near the robot32. The digital camera modules contained within the tray 74 are placedin designated locations 78, which are accurately aligned on then tray74, and oriented such that the robot 32 can select a digital cameramodule from the tray and place the module into a location 81 in a testfixture 80 of a test station 31 a and 31 b.

Continuing to refer to FIG. 2, the handler 30 has two test stations 31 aand 31 b and the robot 32 selects an untested digital camera module 78from the tray 74 positioned at the alignment mark 79, and places a firstmodule into the test fixture 80 of one of the test station 31 a, whichis not being used to perform test, while testing is being performed on asecond digital camera module in the other test station 31 b. This allowsthe time for handling of the modules to be buried within the focus andtest time of the modules. The digital camera module placed onto the testfixture 80 is optically aligned and clamped in place on the testfixture. The first digital module in a first test fixture 80 is alignedwith the optics contained in the test station, and waits completion oftesting of a second digital camera module in the second test stationbefore commencing the focus and testing procedures.

Upon completion of tests on all of the digital camera modules 78contained within a tray 74, the tray is moved to the “tray out” area 77where the manually adjustable lens on modules that have passed the testcriteria are physically fixed into place in the lens fixing area 73,comprising the use of glue or other methods of physically fixing thelens focus in place, such as the use of a laser to weld the lens cap tothe body of the module or pinning the lens cap to the module body. Themodules are then sorted into pass or fail, including differentcategories of pass in the binning area 72 and placed back into plastictrays 69 to be transported from the test system. If the digital cameramodules contained on the tray have a fixed focus or have a variablefocus that is focused by an electrical signal, the modules bypass thelens fixing and are sorted according to the test results in the binningarea 72 and placed into plastic trays 69.

Referring to FIG. 3, a metal tray 74 is shown that is aligned to and isresting on a transport platform 90. The transport platform 90 is alignedto and resting on the conveyor apparatus 75 of the handler 30. Aplurality of digital camera modules 78 is shown positioned on the topsurface of the metal tray 74. Alignment pins 92 are used to maintain thealignment of the digital camera modules 78. An adjustable lens cap 91 isshown protruding above the body of the modules 78. Not shown in FIG. 3are the flex-leads attached to the digital camera modules and theassociated alignment pins.

In FIG. 4 is shown a portion of a metal tray 78 containing a pluralityof digital camera modules 78 with lens caps 91 and a flex-lead 93connecting to a connector PCB (printed circuit board) 94 that contains aconnector 95. Alignment posts 92 are shown, which maintain the alignmentof the module body 78 and the connector PCB 94 to the tray 74. Thealignment of the digital camera modules on the tray is critical for arobot to select the modules and accurately place them into a testfixture. The test handler 30 scans for missing modules 96 to prevent therobot from trying to select a module that does not exist and to provideto a test map of the modules on the tray 74 and identification of anymissing product.

In FIG. 5A is shown a vacuum unit 100 connected to the robot 32. Therobot uses the vacuum unit to pick up from a metal tray 74 a digitalcamera module comprising the module 78, flex-lead strip 93, connectorPCB 94 and connector 95, and place the digital camera module into a testfixture. A plurality of vacuum tubes 101 makes contact along the lengthof the flex lead strip 93 of the digital camera module. The robottranslates the orientation of the digital camera module on a metal tray74 into an aligned orientation in a test fixture 80. The number ofvacuum tubes depends on the length of the flex-leads and the requirementto maintain the digital camera module in a position that can beautomatically placed into the test fixture 80. The alignment in the tray74 is critical to the ability of the robot 32 to position the module 78into the test fixture 80, which will allow alignment with the opticssystem of a station 31 a or 31 b and to make an electrical contact tothe connector 95. After testing is completed, the robot using the vacuumunit 100 lifts the digital camera module from the test fixture and movesthe digital camera module back to the metal tray 74. The module 78,flex-leads 93 and the connector PCB 94 are re-orientated in the originallocation and position on the tray 74.

FIG. 5B shows a view of the contact of the vacuum tubes 101 to theflex-lead strip 93. The lens cap 91 is shown as an hexagonal shape thatfacilitates contact to the focus unit of the test station. Other shapessuch as cylindrical, oval and rectangular can be used and require afocus unit that can grasp the lens cap and make accurate adjustments tothe focus of the module 78.

In FIG. 6A is an isometric view of a digital camera module MUT 78 andits flex-strip leads 93 positioned on a platform of test fixture 80.Appearing from under a probe holder 110 is the PCB 94 that is attachesthe leads of the flex-strip 93 to the electrical connector 95. The PCBis resting on a pad 113, which insulates the PCB 94 and flex strip 93from the test fixture platform 80 and provides a cushion to the PCB whenthe electrical connector 45 is being contacted by the probes 115 (shownin FIG. 6B). A pair of clamps 111 actuated by an electrically operatedclamp actuator 112 hold the MUT 78 in position by pressing on oppositesides of the MUT. The probe holder 110 makes electrical connection toall the leads of the connector 95 with probes connected to pinelectronics so that the MUT 78 can be controlled and tests can beperformed.

FIG. 6B shows a cross section view of the probe holder 110 over the areaof the PCB 94. A probe board 116 contains electrical probes 115 that areput in contact with the electrical contacts 117 of the connector 95 ofthe PCB 94 connected to the flex-strip 93. All electrical contacts 117are connected to a separate probe 115 and the resulting connection iselectrically connected to the pin electronics of the tester. The pad 113provides a cushion to forces applied to the PCB 94 by the probe holderand insulates the PCB from the surface of the test fixture 80

FIG. 7 is an isometric view of a portion of a test station 31 showingtarget wheels 120, the outer casing of a field lens 121, the outercasing of a focus unit 122 the optical reference line 123 and light fromthe light source 124. The optical reference line 123 is an imaginaryline running from the light source 124 through the center of an apertureof the target wheels 120, the center of the field lens 121 and thecenter of the focus unit 122. The light source uses LED's (lightemitting diodes) of different colors, comprising red, blue, green andinfrared.

Continuing to refer to FIG. 7, the test fixture 80 is shown with the MUT78, the flex-lead 93 and the PCB 94 in an unclamped position and pulledback from the optical system comprising the target wheels 120, fieldlens 121, focus unit 122 and light source 124. The module clamps 111controlled by the clamp actuator 112 are open, and the probe holder 110is also pulled back from contact with the connector 95 on the PCB 94. Inthis position the MUT 78 can be lifted out of the test fixture 80 by thevacuum unit 100 attached to the robot 32. When the MUT 78 and itsconnector 95 (FIG. 6B) are clamped into position, the test fixture 80 isthen positioned 125 to locate the lens of the MUT 78 under the opticalreference line 123. The focus unit 122 is brought into physical contactwith the lens cap 91 (FIG. 6A) of the MUT 78, and a stepper motor in thefocus unit 122 adjusts the focus of the MUT 78.

In FIG. 8A is shown a top view of a focus apparatus 130. At the centeris a lens cap 91 of a digital camera module that is focused by turningthe lens cap. The lens cap 91 is surrounded by an access hole 131 in thefocus apparatus, which has a shape that matches the shape of the lenscap 91. In the center of the lens cap is a light hole 136 that allowslight to fall onto a lens 133 and subsequently on a light sensitivedevice 134 within the digital camera module 78 through a lens 133, shownin FIG. 8B. In the view shown in FIG. 8A, the lens cap 91 and the accesshole 131 in the focus apparatus 130 have a hexagonal shape where theaccess hole 131 of the focus apparatus 130 is slightly larger than thelens cap 91. Other shapes are can be used for the lens cap 91 with therequirement that the focus apparatus 130 have an access hole shape or anequivalent mechanism to physically adapt to the lens cap 91 for purposeof turning the lens during a focus operation. A belt 132 or equivalentmechanism connects the focus element 130 to a stepper motor 137 to allowthe adjustment of the focus of the MUT 78 by turning the focus elementin both directions.

FIG. 8B shows a cross section of the focus element 130 and the MUT 78.The lens focus apparatus access hole 131 is shown around sides of thelens cap 91. A photosensitive semiconductor device 134 is centeredwithin the MUT 78 under the optical axis of the lens 133. The lens cap91 is turned by the focus element 130 using the belt 132 connected to astepper motor until light of an image being viewed by the digital cameramodule is in focus on the photosensitive device 134. The inner shape 135of the focus apparatus 130 is angled so as to not inhibit lightemanating from a focus target from falling on the lens 133.

In FIG. 9 is shown a flow diagram of the method of adjusting the focusof a digital camera module. A module is loaded into a test fixture of atest station of the handler 230. Electrical contact is made to themodule electrical leads 231, which allows the module to be powered andto receive and send electrical signals. The module lens is aligned underthe optical unit of the test station 232. A target within the opticalunit is selected and positioned over the digital camera module 233. Thepositioning of the target over the digital camera module includes theoptical distance of the target from the module. A stepper motor drivenfocus unit is brought in contact with the lens cap of a module with amanually adjustable lens 234.

Continuing to refer to FIG. 9, the shape of the lens cap dictates theshape of the portion of the focus unit that is in contact with the lenscap. The preferred shape is hexagonal for ease of mating of the lens capand the focus unit and at the same time allowing accurate adjustment ofthe lens cap. However other lens cap shapes can be used which willrequire changes to the part of the focus unit that contacts the lens capof the module. Other shapes include round, round with a flat, square andoctagonal. The stepper driven focus unit adjusts the focus of thedigital camera module by stepping in fine increments past a point ofmaximum image brightness of the module 235. If a digital camera modulewith a fixed focus is tested, the focus unit is not used, and the fixedfocus is tested to determine if the fixed focus module meetsspecifications. If a module with an electrically variable focus istested, the test system controls the focus with electrical signals,checking that the electrically variable focus meets specification overthe focus range of the module.

Continuing to refer to FIG. 9, an analog picture image is measured forpicture brightness 236. The brightness of the picture image is fed backto a control unit 237, which controls the stepper motor. The steppermotor turns the part of the focus unit in contact with the module cap inincrements until the point of maximum brightness is passed 238. Then thestepper motor is control to reverse direction with small step incrementsand stopping at the closest stepper motor step to the point wheremaximum brightness occurred 239. The focus adjustment is ended 240 andthe focus adjustment 239 is maintained throughout the remainder on thetesting and handling within the test handler 241.

In FIG. 10 is a flow diagram for transporting digital camera modules. Acarrying tray with digital camera modules for test is brought to thehandler 180. The carrying tray can be of any material, such as plastic,but it is not dimensionally accurate and does not hold the camera modulewith sufficient accuracy to be used in the test handler. The carryingtray can be any size and is not required to contain the same number ofmodules as a metal tray used to transport untested modules through thehandler. The digital camera modules on the carrying tray are transferredto the metal tray 181. The modules placed onto the metal tray in anaccurate orientation to allow selection by a robot at a test station.The metal tray with untested digital camera modules is transported on aconveyor to an alignment mark 182. The alignment mark is near a robotused to select modules for focus and test from the tray by the robot.The digital camera modules are focused and tested 183 and returned tothe metal tray by the robot oriented in the original position 184. Thetested modules are transported by the conveyor of the handler on themetal tray to a lens fixing and module binning area 185. After the lenscap of the module has been permanently fixed to the body of the module,the tested digital camera modules are sorted into bins comprisingcarrying trays 186. The carrying trays are then used to carry the testedmodules from the test handler 187.

In FIG. 11 is a flow diagram of the method of the handling of digitalcamera modules within the test handler 30 of the present invention. Ametal tray containing a plurality of digital camera modules is loadedinto the handler 190. The tray is of metal construction to meet thetolerance requirements of the handler, whereby the digital cameramodules are accurately located on the metal tray with alignment poststhat maintain alignment throughout the operations of the handler.Material other than metal can be used in place of the metal tray;however, the non-metallic material must meet stringent tolerances andaccurately position the digital camera modules so the modules can beselected by the robot and accurately oriented in a test fixture. Themetal tray normally contains digital camera modules of the same partnumber, but it is within the scope of the present invention that thetray contain can contain a plurality of part numbers. This may requireone part number to be tested in one test station and another part numbertested in another test station. The metal tray is aligned with areference mark 191 located near a robot. The robot is used to select adigital camera module from the tray, orient and place the module into atest station. Modules missing from the tray are detected 192 and therobot selects a digital camera module 193.

Continuing to refer to FIG. 11, the lens and I/O test points of theselected digital camera module are optically aligned 194. The digitalcamera module is then placed into a test fixture of a first test station195 and clamped into position 196. The digital camera module ispositioned under an optical reference line and the electrical contactarea of the test station 197. Electrical contact is made to the I/Oleads of the modules 198 using an electrical contactor probe having aplurality of electrical contacts, and then focus and test routines arestarted 199. Electrical contact is made to all I/O leads of the module.Electrical tests comprise of DC tests for continuity, current,functionality and module temperature. Photonic testing of the photosensitive device within the digital camera module comprises colorsensitivity and leakage, dark current, bad pixels, noise, anddistortion. A second module is loaded into a second test station 200using the robot to select the next digital camera module from the metaltray 193, after which the second module is optically aligned 194 andplaced into a test fixture of the second test station 195. The pre-testoperations continue on the second digital camera module while the firstdigital camera module is being focused and tested. This buries the timeto handle the second module within the test time of the first module.

Continuing to refer to FIG. 11, when the test on the first digitalcamera module ends 201, the first digital camera module is place backinto the metal tray by the robot in its original location in the tray,and the focus and test routines are started on the second module 199. Ifall the modules in the tray are not tested 202, a third module isselected by the robot 203 and 193 to go through the placement andalignment operations 193, 194, 195, 196, 197 and 198 in the test fixtureof a test station not being used for test operations while the seconddigital camera module is finishing the focus and testing operations.

Continuing to refer to FIG. 11, if all the modules in a tray have beentested 204 and returned to the metal tray, the tray is moved from thetest stations and a next tray is positioned at the alignment mark tobegin the next series of focus and tests. A tray map is generatedidentifying test results for each module 205 so that the tray can beunloaded 207 and the modules placed in the appropriate part number binsfor the tested module. Before the tray is unloaded into bins, manualfocus modules with a focus adjusted during test are processed throughthe lens-fixing step 206. Lens fixing comprises gluing the lens cap tothe body of the digital camera module. Other lens fixing techniques canbe used such as using a laser to weld the lens cap to the body of themodule or by a mechanical method such as using a pin to prevent the lenscap from turning and destroying the focus.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade without departing from the spirit and scope of the invention.

1. A method of loading and testing miniature digital camera modules,comprising: a) loading a tray with a plurality of digital cameramodules, b) positioning said tray at a plurality of test stations, c)overlapping a loading of said plurality of the modules onto said teststations for a focus and test of said plurality of modules, d) movingsaid tray containing tested modules to a focus fixing area, e)positioning a next tray at said plurality of test stations and repeatingsteps c and d for said second tray, f) generating a test map of saidtested modules, g) fixing said focus of said tested modules, h) sortingsaid tested modules into part number bins.
 2. The method of claim 1,wherein said tray is a metal tray.
 3. The method of claim 1, whereinsaid focus is maintained throughout subsequent testing and handling. 4.The method of claim 1, wherein said test further comprises: a) DC tests,b) photonic testing of the light sensitive device contained within saidmodules.
 5. The method of claim 1, wherein said tray further comprises:a) said plurality of digital camera modules oriented and positioned forselection by a robot, b) each module of said plurality of moduleslocated with alignment pins mounted on said tray.
 6. The method of claim5, wherein said alignment pins on said tray position a body of saidmodules and a PCB (printed circuit board) of an electrical connector ofsaid modules.
 7. The method of claim 1, wherein the positioning of saidtray further comprises: a) placing said tray on a conveyor apparatus, b)moving said tray with said conveyor, c) locating said tray at analignment mark near said plurality of test stations.
 8. The method ofclaim 1, wherein the plurality of test stations is one.
 9. The method ofclaim 1, wherein the plurality of test stations is two.
 10. The methodof claim 9, wherein said overlapping of the loading with the focus andtesting of said plurality of modules further comprises: a) loading afirst test station with a first module of said plurality of digitalcamera modules, b) starting focus and test routines on said firstmodule, then c) loading a second test station with a second module ofsaid plurality of digital camera modules, then d) ending said focus andtest routines on said first module, then e) starting focus and testroutines on said second module and loading a third module of saidplurality of digital camera modules into the first test station, then f)repeating said overlap of loading with focus and testing until saidplurality of digital camera modules is tested.
 11. The method of claim10, wherein said loading further comprises: a) selecting said pluralityof modules with a robot, b) orienting said modules into a test fixturein said first and second test stations, c) clamping said modules intosaid test fixture, d) positioning said modules under an opticalreference line and electrical contacts, e) making electrical contact toelectrical leads of said modules, f) unloading said test fixture withsaid robot after completion of focus and test routines.
 12. The methodof claim 11, wherein selecting said plurality of modules with said robotuses a vacuum unit to contact a flex-strip containing electrical leadsof said modules to select said modules and to lift the modules from thetray and place the modules into said test fixture of said test stations.13. The method of claim 12, wherein said vacuum unit contains aplurality of tubes that are used to apply a vacuum simultaneously tosaid flex-strip to lift the module from said tray.
 14. The method ofclaim 11, wherein unloading said test fixture with said robot uses avacuum unit to contact a flex-strip containing electrical leads of saidmodules in said test fixture to lift the modules from the test fixtureand place the modules back onto said tray.
 15. The method of claim 14,wherein said vacuum unit contains a plurality of tubes that are used toapply a vacuum simultaneously to said flex-strip to lift the module fromsaid test stations.
 16. The method of claim 14, wherein said robotunloads said test fixture by placing said modules onto the tray in anorientation and position from which the modules were originallyselected.
 17. The method of claim 11, wherein said clamping uses a clampactuator which positions clamping elements in firm contact with twoopposite sides of a body of said modules.
 18. The method of claim 11,wherein said electrical contact is made to said electrical leads of saidmodules by a set of probes.
 19. The method of claim 18, wherein said setof probes makes contact with a connector located on a PCB (printedcircuit board) connected to said electrical leads.
 20. The method ofclaim 1, wherein said fixing of the focus of tested modules uses glue topermanently bond a lens cap to a body of said modules with a manualfocus.
 21. The method of claim 20, wherein said fixing of the focus oftested modules uses a laser to weld said lens cap to said body of themodules.
 22. The method of claim 20, wherein said fixing of the focus oftested modules uses a pin to physically fix said lens cap to said body.23. The method of claim 1, wherein said sorting of the tested modulesuses said test map to determine which module is placed into said partnumber bins.
 24. The method of claim 23, wherein said part number binsinclude bins for containing said tested modules with a test result thatare a variation of a test specification.
 25. A method for handling andtesting miniature digital camera modules, comprising: a) loading a traywith a plurality of digital camera modules, b) moving said tray near arobot of a handler, c) loading a first module of said plurality ofmodules into a first test station, then d) starting focus and testroutines on said first module, then e) loading a second module of saidplurality of modules into a second test station, then f) ending saidfocus and test routines on said first module, then g) starting saidfocus and test routines on said second module, then h) unloading saidfirst module from said first station and loading said first test stationwith a third module of said plurality of modules, then i) ending saidfocus and test routines on said second module and starting said focusand test routines on said third module, then i) continuing an overlappedload and test of said plurality of modules until said plurality ofmodules on said tray are focused and tested, then j) generating a testmap of said plurality of modules, then k) moving said tray to a “trayout” area of said handler, l) fixing said focus of said modules having amanual focus, m) sorting said modules into part number bins.
 26. Themethod of claim 25, wherein loading said tray places said modules indesignated locations on said tray aligned with alignment pins.
 27. Themethod of claim 25, wherein moving said tray near said robot uses aconveyor apparatus to position said tray at an alignment mark.
 28. Themethod of claim 25, wherein loading said first module into said firsttest station uses said robot to select said first module with a vacuumunit, whereby said first module is oriented into a test fixture of thefirst test station, clamped in the test fixture and electrical contactmade to electrical leads of said first module.
 29. The method of claim25, wherein loading a second module into a second test station uses saidrobot to position the second module during focus and testing of saidfirst module, which buries a loading time of said second module within afocus and test time of said first module.
 30. The method of claim 25,wherein unloading said first module from the test fixture uses saidrobot to select said first module with a vacuum unit and orient saidfirst module onto said tray in a position and orientation originallyoccupied by said first module.
 31. The method of claim 25, whereinmoving said tray to said “tray out” area uses a conveyor apparatus. 32.The method of claim 25, wherein fixing said focus on said module havingsaid manual focus permanently connects a lens cap to a body of saidmodule.
 33. The method of claim 32, wherein permanently connecting saidcap to said body uses glue.
 34. The method of claim 32, whereinpermanently connecting said cap to said body uses a laser to weld thecap to the body.
 35. The method of claim 32, wherein permanentlyconnecting said cap to said body uses a pin to prevent turning of saidlens cap.
 36. The method of claim 25, wherein sorting said modules intopart numbers bins uses said test map to determine which part number binsaid module is to be placed.
 37. A method of transporting miniaturedigital camera modules, comprising: a) carrying untested digital cameramodules to a test handler in a carrying tray, b) transferring saiduntested modules to a handler tray, c) transporting said handler traypopulated with untested modules to an alignment mark near a robot withinsaid test handler using a conveyor, d) selecting untested modules fromsaid handler tray using said robot, e) returning tested modules to saidhandler tray using said robot, d) transporting said handler tray withtested modules to a lens fixing and binning area, e) transferring saidtested modules that are sorted to said carrying trays in said binningarea.
 38. The method of claim 37, wherein said carrying trayapproximately positions said untested modules.
 39. The method of claim38, wherein said carrying tray is plastic with loose tolerances.
 40. Themethod of claim 37, wherein said handler tray accurately positions saidmodules for selection by said robot.
 41. The method of claim 40, whereinsaid handler tray is metal with tight tolerances.
 42. A handler fortesting miniature digital camera modules, comprising: a) a carrying trayb) a handler tray, c) a tray in area, d) a conveyor, e) an alignmentmark, f) a tray out area, g) a lens fixing area, h) a binning area, i)said carrying tray transports untested digital camera modules to a testhandler from where said untested modules are transferred to said handlertray, j) said conveyer transports said handler tray from said tray inarea to said alignment mark, k) said conveyer transports said handlertray containing tested digital camera modules from said alignment markto said tray out area, and wherefrom said lens are fixed and saidmodules are sorted into said carrying tray in said binning area.
 43. Thetest handler of claim 42, wherein said handler tray accurately positionssaid untested modules for selection and orientation into a test fixtureby a robot.
 44. The test handler of claim 43, wherein said handler trayis metal.
 45. The test handler of claim 43, wherein said handler traycontains alignment pins to accurately maintain position of said untestedmodules.
 46. The test handler of claim 42, wherein said carrying traymaintains approximate location of said untested modules.
 47. The testhandler of claim 46, wherein said carrying tray is plastic.
 48. The testhandler of claim 42, wherein said lens fixing area permanently fixes alens cap to a body of said tested modules.
 49. The test handler of claim42, wherein said handler tray reloaded with said plurality of testedmodules is unloaded according to test results into said carrying traylocated in said binning area.